Advanced Crashworthy Self-Sealing (ACWSS) Fuel Bladder

The objective of this Composites Manufacturing Technology Center (CMTC) project is to develop new crashworthy, self-sealing fuel bladders using modern manufacturing methods for production. The focus is on material development of an advanced composite construction to enhance low fuel permeability and resistance, structural toughness, and self-sealing performance, while reducing weight and susceptibility to damage during handling / installation.

Fuel bladders resulting from this effort are anticipated to improve availability, affordability, and maintainability. Response Technology’s advanced manufacturing processes, improvements in automation, and seamless bladder designs will reduce defects and reworks in the end-product. Projected cost savings per bladder are approximately 25 percent due to efficiencies gained in material and manufacturing. Lead and cycle times will be improved over legacy fuel bladder manufacturing from 6 to 8 weeks to under 10 days.

These improvements are expected to reduce weight of fuel bladders by up to 40 percent compared with the current design. Response Technology’s new bladders are anticipated to meet the full life expectancy, which will help reduce the number of non-mission capable aircraft and general aircraft downtime due to early failures of fuel bladders. From a maintenance and installation perspective, the resulting fuel bladders will be lighter, more flexible, and less prone to damage, which will allow the maintainers to more easily maneuver the fuel bladders into the fuel cavity for installation. The anticipated reduction in fuel cell replacement costs is ~60 percent.

The total anticipated savings for the V-22 Osprey platform in production costs and maintenance is expected to be $22.0K per unit, which equates to $87.0M in program savings.

After successful completion of all qualification testing for each bladder position, the Naval Air Warfare Center, Aircraft Division (NAWCAD) Technical Warrant Holder for Mechanical Systems, or his / her designee, will issue a letter to the Defense Logistics Agency (DLA) and/or the Naval Supply Systems Command (NAVSUP) authorizing Response Technologies as an approved supplier of U.S Navy / Marine Corps aviation fuel bladders. The V-22 Program Office will execute a Production Readiness Review with Response Technology to confirm readiness / ability to manufacture their specific fuel bladder designs. Implementation is anticipated in FY2027.

*Prepared under ONR Contract N00014-21-D-7001 as part of the Navy ManTech Program.

*DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. DCN# 2024-11-6-309; Approval Date: 11/14/2024